Method of preparing cotton batting for shipment and use



Dec. 11,` 1928. M J STACK I1,694,954

METHOD 0F PREPARIG COTT; BATTING FOR SHIPMENT AND USE l l Filed oct. 7, 1926 s sheets-sheet 1 0' vf'f'ff/jff a f 4 i(ll f fx, d Q ty I w I mii-a1 ./M" -/V//./f`/'7 v JIL f/ -f/ fr, /f if I/ WW MM miwwwM\\\\\\\\\sff f2 'Dagli will v @X \\\\\.z Q ws- ,fr

*Y Dec. 11, 1928. 1,694,954

M. J. STACK METHOD 0F PREPARING COTTON BATTING FOR SHIPMENT ND USE -giq- -m'g'l "INVENTOR Malice Jtacj.

METHOD 0F PREPARING COTTON BATTIG FOR SHIPMENT AND USEl Filed oct. 7. 1925 ,s sheets-sheet 5 INVENTOR @WMM A ATTORNEY Patented Deu 11, 1928.r

UNITED smissf lentreNr )Fiflca` MAUR-ICE J. STACK, 0F COHOES, YORK, ASSIGLOR TO BBINTIIALL MNUFACTUR? lG CQMPANY, ENC. OF DELAVVRE, GF WILMNGTON, DELAWARE, A CORPORA- TON OF DELAW'ARE.

Y METID OF IPREYARING COTTON BATTNGj FOR SHPMENT AND USE..`

Application led october 7, 1926, Serial No. 140,138, andv in Canada March 27, 1925.

My invention hasfor its object to provide a new and improved method of preparingA and handling cotton batting used in automobile and lsimilar upholstery and to prepare the same for shipment and use in a more eii'icient and economic manner than has heretofore been possible and by the use of which a more perfectly conditioned finished product is made possible and a very great saving ofshipping and storage space effected.

According to the practice before 'my invention cotton batting Was prepared by taking a sheet of batting and folding it over upon itself longitudinally into a continuous bat, the folding being done around an insert or core of paper, fabric, or other material.`

ln Some forms of bats a double folding method is used and the paperstrip is eme pl-oyed to gum the folds together. In all methods heretofore used, however, the bat when it comes from the folding machine is of a more or less elliptical cross section. i In the method now most commonly used for shipping bats the'bat 'is laid zigzag fashion in a narrow box 'by back and forth movement which alternately brings the last fold of the bat on top and underneath so that in making the bend from one fold to another the bat is frequently opened at the bends or deformed resulting' in an unsatisfactory condition when the bat is removed from the package for stuiiinginto pleats It is one of the objects of my present inf vention to eliminate the above mentioned objectionable fea-tures and to so condition the bat after it leaves the forming machine that When it is unWound for use the bat Will be compact and instead of an elliptical cross section it will be retained in approximately a rectangular cross section. y

Again it is the object of the invention to provide a method of baling the bat whereby all danger of deforming the bat andk the` folds of the bat slipping on each other or .coming loose oropening up is eliminated.

The method which constitues the subject matter of my invention Will be clearly understood by those skilled in the artl from the ,sheet and woundl into a roll ork cylindrical batconstituting one of the steps of the pres-l -ent method. ,o v

Figures 2 and 3 are perspectivevievvs of a rollof batting formed as indicated in Figure l as Vviewed `from the side and end respectively. p g

Figure 4 illustrates diagrammatically the manner in Which pressure is applied to a plurality of rolls of batting to perform the dual function of constraining the mais to a greatly reduced shipping volume andvproviding the primary step toward the ultimate shaping of the lengths of batting tothe desired substantially rectangular and relatively tlat cross sectional shape.

Figure 5 illustrates diagrammatically the manner in Whichthe constrainedmass of batting rolls are securely retained in` their volume reduced batting length pressed con` dition for being stored and shipped so that the fibres of the Vbatting' Will become set to Y the desired condition because of such confinement and storage before or during shipping or during both.

Figure 6 illustrates a completed `bale of batting rolls ready for storage and shipping.

Figure 7 illustrates the contents of a bale'.

length and shows the primary condition of the same as it leaves the forming machine.

Figure 10 is a View similar vto Figure y9 and illustrates a section of battingcompleted by use of my improved method and ready for use. n i

' Figure l1 is a view similar to Figure 9 1llustrating another type of folded bat as it comes from the folding machine in its primary or partially completed condition.

Figure 12 is a vie7 similar to Figure 10 illustrating the bat shown in Figure 11 after it has been completed, i. e., the condition the bat is in when it is heilig unWound in the manner indicated in Figure 8.

In the drawings, 1 represents the bat forming machine which may be of the general construction of that disclosed in my patent No. 1,496,952, issued June 10, 1924 and which is adapted to take a sheet of cotton batting, fold it longitudinally on itself into the cross sectional form indicated in Figure 9, or into other cross sectional forms such for instance as that indicated in Figure 11. When the bat comes from the forming machine in its folded condition it is more or less resilient and assumes an approximately elliptical form in cross section. see Figure 9, see dotted lines also in Figure 11. As the bat comes from the folding machine the last' fold is on top, that is to say, the last fold 2 of the continuous bat 2 lies uppermost, or the double fold 2"--2x in Figure 11 lies uppermost. The loosely folded bat usually contains a paper or other insert strip 2 which may be gummed or not as desired. If the fold indicated in Figure 11 is used the strip is gummed to tend to hold the bat from unfolding.

As the batting length 2 leaves the discharge end of the forming machine 1 it passes over supporting rollers 3, between which a compensatingr loop 4 is permitted to depend in the manner indicated in dotted lines in Figure 1 of the drawings, and it is then Wound spirally in edge to edge layers around Va hollow core 5 into the form of a cylindrical roll 6 as indicated in Figures l, 2 and 3. It Will be understood, of course,

' that the depending loop 4 is made in the batting being rolled during the early portion of the rolling action to compensate for the increasing speed of take-up on the roll core 5 due to the ever increasing circumferential wrapping surface of the roll.

`For accomplishing the above mentioned winding any suitable apparatus such as is indicated in Figure l of the drawings may be utilized. In that illustration, 7 indicates a feeding horn through which the advance end of the batting length is threaded and which is caused alternately to traverse the length of the core 5 from end to end, bobbin Winding fashion, to effect the proper' guiding of the Winding function. A frame 8 serves to support the apparatus which includes the vertical guideway equipped roll end confining Wings 9 and the roll support ing and rotating rollers 10, a pair of the lat ter of which are provided and spaced apart to sustain the roll thereupon and to which rotation is imparted to facilitate the rolling action, through the medium of the power transmission devices 11. A rigid shaft 12 is, of course, inserted through the core 5 as a mandrel to project from the ends thereof and provide trunnions for the roll and coope 'ate with the guidervays of the wings 9. This roll feature provides for 4the desired perfectly normal condition of the batting throughout the entire length thereof and entirely eliminates all twisted, matted and swollen portions Which would greatly reduce the commercial value of the batting.

By Winding the batting on the core with the last fold side orvface adjacent the mandrel all tendency of the last fold to become displaced from the reniainder is avoided as the tendency is to hold the last fold down against slippage. lVhile, of course, the bat may be rolled with the other side adjacent the core, nevertheless better results are obtained by rolling the last fold side facing the core.

ln rolling the bat on the core no tension is applied for the purpose of compacting the mass or effecting a tight winding. On the other hand the Winding is a loose Winding so as not to stretch or elongate the fibres of the bat.

lh'en bats having the, cross section of Figure 11 are Wound it is especially advantageous to Wind them with the lastfoldside 2x-2x facing the core for otherwise practice has demonstrated that when the bat is wound on the core with the last-fold-side aivay from the core there is a tendency for the bat to open up centrally and spread apart, thus deforming the bat and often rendering it unfit for piping. By winding the bat with the folds 2"2c facing the core the forces acting during Winding are so directed as to keep the folds closed along the middle lino and prevent separation or loosening of the cotton from the gummed strip 2, particularly if the glue is still soft as it frequently is when the manufacturing and Winding operations take place rapidly.

One or more of the rolls, formed as above described are then placed in a press or baler as indicated in Figure 4lof the drawings and pressure is applied thereto to reduce the volume of the mass of the roll to a relatively small mass, or in other Words, to change the roll from a large diameter roll bale to a smaller cross section square or angular bale. The purpose of this is twofold, namely, to adapt the bale to occupy a small storage or shipping space and also to impart to the batting lengths the fin al finished pres-` sure designed to effect the final cross sec tional shape and dimensions of the desired completed product. The baler illustrated is of the vertical pressure type and is very convenient in that the burlap or other baling material may be positioned one' sheetabove -prevent the elongation of the bale'in the direction of its axis. Thus when the bale is mounted on the unwindiiig stand and the burlap cover removed therbat when unwound from the bale insteadof being a looseresilient mass of approximately' elliptical cross section which would notA hold its form, the bat comes from the roll inthe condition illustrated in Figures and 12, namely a compacted flat bat, the compacting pressures also serving to cause the fibres'of adjacent layer surfaces to interlock or interengage as it were, thereby aidingvin preventing the unwinding of the Abat as it isf drawn from the roll and fed into the stuffing tool.

It should be understood, of course, that when the compressed bale is released from its burlap covering and put on the stand as shown in Figure 8, it will gradually, reassuine a cylindrical form but the diameter of the cylinder will not return to the original of the cylinder when first wound as indicated in igure 1. e i

The baler which I prefer to use includes the usual confining sides 13, bottom 14, rear wall which mayor may not beremovable as desired, removable front wall 16, pressure applying top 17 pressure exerting devices 18 and any desired travel distance control devices 19.

After the cylindrical rolllias been baled as indicated in Figure 6 the bales are stored for a sufficient time to allow the libres of the batting lengths to become set to-tlieir desired final condition and the final conditioning of the baleis thus effected. This storing may take place in the store'room of the manufacturer or in the storage room of the user, or while the goods are intransit, so long as the bat is permitted to remain baled a sufficient length of time-'to' enable the bat fibres to become set to the desired degree in order that when the batk is iinrolled it may be in the proper shape for -insertion into the pleat pockets.v

Figure 5 of the drawings indicates the i restrained mass in the partly closed burlap envelope and Figure 6 indicates the completed bale. v

When it is desired to use the contents of a bale of batting one thereof is opened, as indicated in Figure 7, from which it will be seen that the'mass reta-ins its constrained condition-.and that the pressureexertedby the baler has no effect whatever toward collapsing the cores 5 but 'that the latter are still in their normal condition and 'adaptablelv for receiving a piece of shafting for. providing means for mounting the individualrolls of batt-ing in the manner indicated .in Figure 8.

During the fwhole of the baling and storage of the batting rolls the process of completing the conditioning of the batting lengths, from that illustrated in Figui-e9 tok that illustrated in Figure 10, goes on.

Then it is desired to use a roll of the batting, it is mounted upon any suitable unwinding stand 20 adaptable forv receiving the triinnions forming rod 21 passed through the core 5 of the roll and provided with antifriction means-22 for supporting that rod and use, by the employment of which notonly is a better bat obtained but the freight vcharges on carload lots arereduced because of the compact naturey of they bales.

square I am aware that prior to my invention i cotton sheeting has been rolled into compart roll bales, the windingbeing conducted under tension to provide a tightly wound bale.V

The sheeting is wound around a mandrelor core Which is afterwards removed and Vdoes t not form a permanent part of the bat, (see for eXamplel the patent to Davenport No.

729,285 issued May 26, 1903). y

I am also aware that prior to my invention it has been proposed to balecotton by g twisting itinto*v a rope` of firmly lcompressed `strands and winding such strands under' tension upon a shaft into the .forin ofa roll bale, e-ncasing the bale into an envelopev and removingit from the 'shaft (see Mota No. 696,743, issued April 1, 1902).

Iam also aware that prior to my invenytion ithas been proposed to twist cotton libres into a looserope and .wind the same arounda mandrel while applying pressure to the coils of the mandrel toV compact or effect a! tension widing of the material, (see for example the pa.teiittofl)i'ake No. 179,849,

issued July 18, 1876).. v

I am also aware that prior to my invention it has been proposed to wind cotton sheeting tightly about a largeinandrel to form a cylindricalbale, then removing the bale of sheet cotton from `the mandrel `and putting it in a compress to form a compact rectangular or square bale, see for example the patent to Luce, No. 864,975, issued September 3, 1907.

In none of the foregoing methods of the prioil art, however is the core permitted to remain in the bale and in no instance is a flat folded bat proposed to be wound. I therefore do not claim broadly the winding of cotton into a cylindrical form and then compressing itl into a rectangular' bale.

The present application in so for as it contains subject matter in common with my application Serial No. 16,078, filed March 16, 1925, is a continuation of that application.

Vhat I claim is:

1. The method of preparing cotton for shipment and use, which consists in taking a sheet of cotton, folding` the same lengthwise over upon itself loosely to constitute a relatively narrow continuous bat of approximately elliptical cross section, winding the bat flatwise loosely on a core in superposed layers as a round bale, compressing the bale, while maintaining the core in place, into a square bale while holding the bale against spreading along the axis of the core, thereby flattening the entire bat within the bale into a form approximately rectangular in cross section and retaining the compressed bale in its compressed condition until ready for use.

2. The method of preparing cotton for shipment and use, which consists in taking a sheet of cotton, folding the same lengthwise over upon itself loosely to constitute a relatively narrow continuous bat of approximately elliptical cross section, winding the bat flatwise loosely on a core with the last-fold surface of the bat facing the core in superposed layers as a round bale, compressing the bale, while maintaining the core in place, into a square bale while holding the bale against spreading along the axis of the core, thereby flattening the entire bat within the bale into a form approximately rectangular in cross section and retaining the compressed bale in its compressed condition until ready for use.

3. The method of preparing cotton foi` shipment and use, which consists in taking a sheet of cotton, folding the same lengthwise over upon itself loosely to constitute a relatively narrow continuous bat of approximately elliptical cross section, winding the bat flatwise loosely on a core in superposed layers as a round bale, compressing the bale, while maintaining the core in place, into a square bale while holding the bale against spreading along the axis of the core, thereby flattening the entire bat within the bale into a form approximately rectangular in c ross section, enclosing the compressed bale in a retaining envelope for a suflicient period of time until the bat becomes set, whereby when the bat is later unwound from the bale for use it will retain an approximately flattened cross section in lieu of the illiptical cross section it had when first wound.

4. The method of preparing cotton for shipment and use, which consists in taking a sheet of cotton, folding the same lengthwise over upon itself loosely to constitute a relatively narrow continuous bat of approximately elliptical cross section, winding the bat flatwise loosely on .a core with the lastfold surface of the bat facing the core in superposed layers as a round bale, compressing the bale, while maintaining the core in place, into a square bale while holding the bale against spreading along the axis of the core, thereby flattening the entire bat within the bale into a form approximately rectangular in cross section, enclosing the compressed bale in a retaining envelope for a sufficient period of time until the bat becomes set, whereby when the bat is later unwound from the bale for use it will retain an approximately flattened cross section in lieu of the elliptical cross section it had when first wound.

5. In a method of preparing upholstery cotton bats of the longitudinally folded type for shipment and use, the steps which comprise the winding of the bat loosely around a core thereby producing a. loose easily deformable bale, taking said bale and restraining it against elongation in the direction of its axis whileholding the core in place, compressing the bale into a rectangular or flat bale without deforming the core, thereby flattening the bat Within the bale as well as compacting the mass of the bale and retaining the compressed bale in its compressed condition until ready for use.

6. In a method of preparing upholstery cotton bats of the longitudinally folded type for shipment and use, the steps which comprise the winding of the bat loosely around a core thereby producing a loose easily deformable bale, taking said bale and restraining it against elongation in the direction of its axis while holding the core in place, compressing the bale into a rectangularV or dat bale without deforming the core, thereby flattening the bat within the bale as well as compacting the mass of the bale, and maintaining the bale compacted for a sufficient time interval to cause the fibres of the bat within the bale to set to a degree suflicient to retain a substantial flattened form of bat in cross section whereby when the bat is later unwound from the bale it will be of an approximately flattened cross section in lieu of the elliptical cross section of the bat when first wound.

7 The method of preparing cotton for 1,694,954y i 5 y shipment and use, which consists of the iol-l Within the bale While maintaining the. core 10 lowing steps in the `order mentioned, Viz: in place and restraining the bale against rst, forming the cotton into a loosely displacement in the direction of the -aXis folded continuous bat, second, Winding the of the core, fourth, holding the bale yin the Y 5 bat latWise loosely on a small hollow core compressed state for a sufficient time ininto a loose cylindrical bale, third, comterval to enable the cotton to become set pressing the bale intera compact bale and substantially as specified. thereby compacting the material of, the bat y MAURICE J. STACK. 

